Method of making lighter plungers



July 22, 1952 T. F. VASSAUX 2,603,355

METHOD OF MAKING LIGHTER PLUNGERS Filed April 22, 1950 H69 fie. 10 56.12

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Arraemsys Patented July 22, 1952 FFICE" This invention relates to a process or method of making plungers for lighters, such as cigar or cigarette lighters.

Certain cigar or cigarette lighters include reciprocating actuating members generally designated in the trade as plungers. These members or plungers comprise plunger rods which are mounted for sliding reciprocation in the lighter casings and which have on their outer ends actu-,- ating cap pieces provided with gear teeth for actuating the lighter mechanisms when the cap pieces and plunger rods are pressed toward the lighter casings. Heretofore the lighter plungers referred tohave' been formed of at least three parts and their production has necessitated excessive manufacturing steps, such as the riveting of finish plates on the cap pieces and the like.

An' object of the invention is to provide a method or process for making lighter plungers whereby the latter can be produced of only two interconnected parts which are readily manufactured by simple, efficient and inexpensive operations and which two parts are secured together in an exceedingly easy and simplified manner.

A further object is to provide a method or process for making lighter plungers wherein the manufacturing and assembling steps are reduced to a minimum and hence manufacturing costs are maintained at a desired low level. I A:further object is to provide a method or process of. producing lighter-plungers wherein the cap pieceis 'a, single part to whichfit is not necessaryito rivet a finish plate and the plunger rod is an easily produced screwmachine product while the cap piece and rod are readily, economically and; efiectively interconnected in an extremely simple manner.

Further and additional objects and advantages of the invention not hereinbefore enumerated will become apparent hereinafter during the detailed description which is to follow and which covers a preferred way of carrying into effect the inventive. concept.

Referring to the accompanying drawing,

I Figs. .1 and 2 illustrate a' sheet metal piece which has been blanked and pierced preliminarily to forming two cap pieces for later assembly with the plunger rod; Fig. 1, being a plan-view of the sheet metal piece and'Fig. 2 a side'edge or elevational view'thereof.

f Figs. 3 andw illustrate the configuration of theblanked and pierced piece of metal after it has been subjected to a first forming operasoiaims. (01.29-148) tion, Fig. 3 being a plan view and elevational view'thereof. I r

Figs. 5 and ,6 illustrate in top plan and side elevation, respectively, the piece of metalafter it Fig. 4 aside has been subjected to a second forming operation.

1 Figs. 'Z and 8 illustrate in top plan andside elevation, respectively, the piece of metal shown in Figs. 5 and 6 but after it has been subjected to a finishing and trimming operation. 7

Figs. 9 and 10 are top'plan and side elevational views, respectively,:of the blank shown in Figs. '7 and 8 after it has been subjected to a separating or severing operation to produce two separate cap piece blanks as well as to a tooth notching operation and a piercing operation.- 1

Figs. 11 and 12 are top plan and sectional views, respectively, through one of the cap pieces shown in Figs. 9 and 10 after the-pilot nib on the plunger rod has been positioned in the opening in the cappiece and the rod brazed, soldered or otherwise secured to the cappieceand also after the outer surface of the cap piece has been subjected to a serrating or scoring operation to impart a decorative appearance thereto- Fig. 13 is a'view similar to Fig. 12 but showing a plunger rod secured to a cap piece which does not have an opening therein and which rod is not provided with a pilotnib, and v Fig. 14 is an elevational view taken looking from the right hand side of Fig. 13.

In accordance with the method contemplated by the present invention the cap piece of the lighter plunger is a stamping and is made from suitable sheetmetal and comprises a single unitary-partu The dies employed in making the cap pieces can be of the progressive type or can be in the form of a series of compound dies. One wa-yof carrying the invention into effect is to blank from a large piece of sheet metal a number of: small pieces 15, see Figs. 1 and 2, and with said pieces I5 each shaped and sized so as to eventually produce after a severing operation two cap pieces.

In blanking the pieces 15 from the large piece of sheet metal each-piece I5 is pierced so as to be provided with a slot l6 of the shape indicated in Fig. 1. The blanked and pierced pieces [5 are thenipla'ced in suitable forming dies and subjected to the first forming operation, after which they have the configuration'shown in Figs. 3 and 4. When the first forming operationhas been performed on the pieces 15 they will have at opposite ends of the slot- I6 and extending longitudinally and centrally of the piece l5 channel-shaped portions l1 while the slot IE will 3 have assumed a rectangular configuration as indicated at I61; and said slot Ifict will have its longitudinal sides defined by upstanding walls 18, the outer ends of which are shaped as indicated at l8a.

Following the first forming operation the pieces l are subjected to a second forming operation to impart thereto the configuration indicated in Figs. 5 and 6. The second forming operation widens th'e'channel portions l1 and provides an external shoulder I9 extending around each channel portion IT as clearly indicated in Figs. 5 and 6. The pieces following the second forming operation are then subjected to :a finish trimming operation after which each piece I5 will have the configuration shown in Figs. '7 and 8.

It will be understood that in subjecting the pieces l5 to the trimming operation they are placed in suitable trimming dies which function tOIISGVQI' fromthe piecesthe flange or flash extending from the edges thereof thatare located at the; open side of I the channel portions.

; Theblank in the form shown in Figs. 7 and 8-- is then 'placediin a suitable die which-:may beof the cam type to separate it into individual cap-. pieces the separationor severance taking place in thewalls l8 of the-slot lfia so as to provide on the adjacent ends. of each cap piece and on both sides'thereof extending lugportions'2ll formed: from the. remaining portions of the WELHS' I8. In this same operation the lug, pore tions'. havezcutth'erein gear teethll which when the cap piece is, assembled 'in a complete lighter meshes with cooperating gear teeth that are-"operatively formed on'and connected with the: operating mechanism. of the lighter, as will be well understood in the art. Also in this same operation each'cap, piece is pierced to provide 2510f. largediameter and'asecond endportion 26-of stilllarger'diameter is .placed in-a suitable assemblingand: pressing die; with? theportion 26 arranged .tozbe'locatedintermediate-the side Walls ofa cap piece. 1 a

The portion 26 ofithe plunger rodis provided withla .pi'lot' nib. 21 :andiwhen' the ;.cap. pieceis positioned in the diewiththe roddocated as shown Figs. 11 Land 12,? the. nibr2'i 'Will .extend :into the opening 22 withv a: pressed. fit when the cap piece: and rod have been; struck byflthe closing of thediesr- Thedieusedafor thislast mentioned operation also finish forms the top andsides'of the cap piece and produces .011 the outerzsurface .of the .cap piece decorative; serraatidnsor markings, as indicated at 28"'in Fig; 11. The capspiece. and the plunger.- 23. attached theretoby the pressed fit referred to'can'nowzbe brazed, welded or otherwise securely.,intercon.- nectedxas'indicated at; 29in Fig.,g,12. The :decorative serrations on the outer surface-of the cap piece act ,to finish the appearance of the'cap piece and obviate the necessity of riveting, to thecap piece. a fin'ishplate as has been the practice-heretofore. g In Figs. 13 and. i l theplunger is illustrated as not havingthe pilotv nib: 2] and thejcap piece asnot beingfprovidedgwith:the opening'22. In this form of construction the;plungenend-ZS of large diameter is so dimensioned as ,to have a close fit in the channeled cap piece,- wherefore 4 the cap piece and plunger can be securely interconnected by brazing, welding, soldering or other means as indicated at 30 in Figs. 13 and 14. Although a preferred form of carrying out the method has been set forth herein, it will be understood that the operative steps may be varied somewhat in accordance with the scope of the appended claims.

Having thus describedwm invention I claim: 1. The method of making" lighter. plungers which comprises blanking from sheet metal byv means of suitable dies a flat blank of predetermined size and of substantially oval shape andsimultaneously by said dies providing therein a slot of substantially I-shape; then subjecting the slotted blank to suitable forming dies to provide: therein channel-shaped portions extending from each end of said slot in longitudinal extension thereof and to change the configuration of said slot to a substantially reccutting. gear teeth :in the separated ends of said sidewalls; then placing each separated" cap piece blank together with a plunger rod having. a portion which. interfits a portion" offthetcap piece blank in a suitable die to .finish 'fo'rm the top and. sides of the cap. piece, press fit the plunger portion .to thecap'piece. portion and decoratively serratethe top. of the .cap. piece; andwthen uniting the. cap piece .porti'on ..to..the plunger rod portion by suitable means such as brazing I Y 2. The: method of: making. lighter. plungers whichicomprises blanking from sheet metal: by means :of suitable :dies a: fiat "blank of predeter-v minedsize and of substantially oval shape and simultaneously by said dies providing therein-a slot of" substantially; I-shape; jthen' subjecting.

the slotted.blankatolsuitable "forming.- dies toprovide 'therein channel shaped portionszextending from each: end of saidtslot in longitudinal. extension thereof and to change the: configuration of said slot to a substantially rectangular .onehaving :upstandingsideiwalls.extending beyond the plane ofthe "base of the= channel-shaped pore tions then -subjecting f the formed 'blank to a second set of *suitable forming dies to further form the blank to widen the channel-shaped portions thereof I and *to provide thereon external shoulders; then subjecting the formed blank to suitable trimming-diesto remove-excess material fromthe free edges thereof; then subjecting thev trimmed blank to' 'suitable diesto the plunger rod portion by suitable means such as brazing.

3. The method of making lighter plungers which comprises blanking from sheet metal by means of suitable dies a flat blank of predetermined size and of substantially oval shape'and simultaneously by said dies providing therein a slot of substantially I-shape; then subjecting the slotted blank to suitable forming dies to provide therein channel-shaped portions extending from each end of said slot in longitudinal extension thereof and to change the configuration of said slot to a substantially rectangular one having upstanding side walls extending beyond the plane of the base of the channel-shaped portions; then subjecting the formed blank to suitable trimming dies to remove excess material from the free edges thereof; then subjecting the trimmed blank to suitable dies to separate the blank midway of the ends of said slot and said simultaneously cutting gear teeth at the separated ends of said side walls and providing an opening in the top of each of said separate cappiece blanks and which is located centrally of the base of the channel-shaped-portion of the separate blank and at a predetermined distance with respect to said gear teeth; then placing each separated cap piece blank together with a plunger rod having a pilot nib on an end thereof which will interfit said opening in a suitable die to finish form the top and sides of the cap piece blank, press fit the pilot nib into said opening and decoratively serrate the top of the cap piece blank; and then uniting the cap piece to the plunger rod by suitable means such as brazing.

THOMAS F. VASSAUX.

No references cited. 

